VW Sharan repair

. Diesel engines: 1,9 l of TDI.
+ 1. Introduction
+ 2. VR6 engine
+ 3. Two-liter engine (ADY)
+ 4. System of greasing of the engine
+ 5. Cooling system
+ 6. System of injection of fuel of the VR6 engine
+ 7. Simos system of injection of fuel of the 2,0-liter engine
+ 8. Ignition system
+ 9. Coupling
+ 10. Mechanical 5-step transmission
+ 11. Shaft of a drive of wheels
+ 12. Hydraulic booster of a steering
+ 13. Forward suspension bracket
+ 14. Back suspension bracket
- 15. Brake system
   + 15.1. Adjustment of brake system
   - 15.2. Disk brakes of forward wheels
      15.2.1. Check of thickness of overlays of brake shoes
      15.2.2. Removal and installation of forward brake shoes
      15.2.3. Dismantling and assembly of the brake mechanism of a forward wheel
      15.2.4. Removal and installation of a brake support of forward wheels
   + 15.3. Brakes of back wheels
   15.4. Processing of brake disks
   + 15.5. Main brake cylinder
   15.6. Check of the vacuum amplifier of a brake drive
   15.7. Pumping of brakes
   + 15.8. Parking brake
   + 15.9. ABS system (anti-blocking brake system)
+ 16. Electric equipment
+ 17. Diesel engine
+ 18. System of greasing of the diesel engine
+ 19. System of cooling of the diesel engine
+ 20. Power supply system of the diesel engine and turbokompressor
+ maintenance Card
+ Specifications and characteristics
+ Elektroskhema

Repair Sharan/Sharan Volkswagen>> Brake system>> Disk brakes of forward wheels>> Removal and installation of forward brake shoes
Operation on replacement of brake shoes carry out independently only in case there is an experience of this sort of carrying out works as traffic safety and a personal security depend on it.
On the car it is necessary to establish only the brake mechanism from ATE (Teves) and brake shoes recommended by manufacturing firm of the car of brands.

Brake shoes change only in a set. At all do not rearrange a block from outer side of a brake disk on internal and on the contrary to balance possible wear. Establish only the details recommended by "Volkswagen".

If it is planned to establish old brake shoes, before their removal mark with paint (a marker, a core) a relative positioning of brake shoes in relation to supports that at installation not to mix internal and external brake shoes and a wheel on which they were established. Removal of forward brake shoes carry out in the following order:
- slightly release bolts of fastening of forward wheels;
- mark with paint (marker) a relative positioning of wheels, brake disks and naves of wheels;
- lift a forward part of the car, put it on a support, unscrew bolts of fastening and remove forward wheels;

Fig. 312. Removal of a spring collar from a bracket of the disk wheel brake mechanism

- insert a screw-driver into a spring collar (fig. 312) and remove it from the fastening in the case of a brake support;

Fig. 313. The locations of protective caps of directing fingers (are shown by shooters)

- by means of a narrow screw-driver take protective caps (fig. 313) of directing fingers;

Fig. 314. Otvorachivaniye of the bottom and top directing fingers (bolts of fastening of a support do not turn out)

- unscrew the bottom and top directing fingers from a support a face six-sided key (fig. 314) and take out them;

Fig. 315. Brake mechanism of a forward wheel: 1 — a disk of the brake mechanism, thickness of 25 mm; 2 — a bolt with an internal shestigrannik, 10 N · m; 3 — a bolt of a power shaft, 200 N · m; 4 — a wheel bolt, 140 N · m; 5 — a protective casing; 6 — a bolt, 10 N · m; 7 — the sensor of ABS system defining frequency of rotation of a wheel; 8 — a bolt, 10 N · m; 9 — a gear rim of the sensor of frequency of rotation; 10 — a brake hose; 11 — a protective cap; 12 — a directing finger, 25 N · m; 13 — the sliding plug; 14 — bolts, 200 N · m; 15 — the brake cylinder assembled with a support; 16 — a spring collar; 17 — a bracket (directing blocks); 18 — brake shoes

- raise a brake support, having moved it up and back, and tie up it to a body a wire bracket. A brake hose 10 (fig. 315) do not disconnect, it should not be overwound, bent and be tense;
- disconnect an internal brake shoe from the brake piston and take it together with a clamping bracket;
- take from a brake support an external brake shoe. If it became attached, carefully separate it by means of a screw-driver.

It is forbidden to press a brake pedal as it will lead to piston loss from the brake cylinder, to an effluence of brake liquid and system depressurization at the removed brake shoes.

Check of a technical condition of the brake mechanism carry out before installation of forward blocks in the following order:
- clear all details and attentively check their condition;
- check a condition of a surface of the piston and the cylinder. At their wear, damage or a strong korrodirovaniye replace the cylinder and the piston. From the cylinder case corrosion remove with a wire brush;
- carefully clear directing surfaces and installation sites of blocks in an aperture of the case a soft metal brush and wipe rags moistened in alcohol (gasoline it is impossible to use). Do not use thus maslosoderzhashchy solutions or sharp tools;

All works on cleaning of brake mechanisms carry out in means of protection of respiratory organs — respirators as the dust from the brake shoes, being allocated as a result of functioning of brake mechanisms is unhealthy.

- check, whether in openings of a bracket of the disk brake mechanism protective caps of directing fingers well sit. The hardened, torn protective caps replace;
- check fingers purity of working surfaces of brake disks. Remove from them oil and dirt. On its surface teases are not allowed, the buckling, deep risks, and also other damages from which wear of slips increases or decreases efficiency of braking. Polishing or a disk pro-point at the same time from two parties is allowed, but thus both parties should be processed on identical depth, and the thickness of a disk should not be less admissible;

Brake disks with a korrodirovanny brake surface are subject to replacement.

- measure real thickness of brake disks and overlays of brake shoes. Brake disks with a dark blue or gray raid before installation of new blocks should be cleared;
- check, whether there are no cracks on a dustproof cap of the piston of the brake cylinder. The damaged dustproof cap urgently replace, as the getting dust quickly leads to emergence of leakage of brake liquid.
Installation of forward brake shoes carry out in the following order:
- remove a protective sticky film from a basic surface of an external brake shoe and accurately establish a block in a support;

Fig. 316. Piston installation in the brake cylinder by means of a clamp

- by means of a vice (fig. 316) or a wooden (plastic) opravka without distortions move the piston in the brake cylinder. Watch to damaging a surface of the piston and a dustproof cap. At cave-in of the piston there is an increase of level of brake liquid in a compensatory tank, therefore before an utaplivaniye of the piston pump out from a tank a siphon pear a part of liquid not to allow its vypleskivaniye from a tank;
- together with the assistant check ease of a piston stroke. For this purpose in a support establish wooden whetstone, slowly press and release a brake pedal. The piston of the brake cylinder should leave and enter easily back (thus other brake mechanisms should be in working condition);
- establish clips an internal brake shoe in the cylinder piston;
- establish an external brake shoe in a support, a slip to a brake disk. Blocks should be pure and precisely enter into the directing;

At installation of brake shoes do not damage being glued substance on a metal plate.

- carefully establish a brake support on a brake disk, in its working situation, enter clean directing fingers, turn and alternately tighten them the moment of 25 N · m;
- put on heads of directing fingers protective caps;
- establish on a support a spring of brake shoes. At the wrong installation the automatic eyeliner of an external brake shoe does not operate;
- several times strongly press a brake pedal, yet will not feel strong counteraction. Thus brake shoes will occupy the working situation and will provide a good prileganiye to a brake disk;
- pump over brake system if it is necessary;
- establish and temporarily fix (by hand) bolts of fastening of wheels;
- lower the car and tighten bolts of fastening of wheels cross-wise;
- check connections on tightness. Podtekaniye of liquid is not allowed;
- check level of brake liquid in a compensatory tank and restore it to demanded level;
- check tightness of brake system on the working engine. For what press several times a pedal of a brake and hold it within several seconds. The pedal thus should not просаживаться.

In process extra earnings of new brake shoes sharp and long braking to a full stop is not recommended.